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Abstract:

One embodiment is a filter element including an outer filter media and an
inner filter media. The outer filter media is operable to remove
particulates present in a flow of fluid and/or coalesce water contained
in the flow of fluid. The inner filter media is operable to remove
particulates from the flow of fluid, separate water form the flow of
fluid, and remove particulates from the flow of fluid. Other embodiments
include unique apparatus, devices, systems, and methods relating to fuel
filters and filtration. Further embodiments, forms, objects, features,
advantages, aspects, and benefits of the present application shall become
apparent from the detailed description and figures included herewith.

Claims:

1-40. (canceled)

41. A method, comprising:directing a flow of fuel to a filter;directing
the entire flow of fuel through a first multi-layered filter media which
is designed to coalesce water in the flow of fuel form water droplets
that flow toward a lower portion of the filter and designed to capture
particulates contained in the flow of fuel;allowing the coalesced water
droplets to flow toward the lower portion of the filter by introducing
the entire flow of fuel into a gap formed between the first multi-layered
filter media and a second multi-layered filter media;directing the entire
flow of fuel from the gap through the second multi-layered filter media
which is designed to separate remaining water droplets from the flow of
fuel and designed to capture particulates contained in the flow of fuel;
anddirecting the entire flow of fuel from the second multi-layered filter
media into an internal fluid chamber of the filter from where the fuel is
directed out of the filter.

43. The method of claim 41, wherein the second multi-layered filter media
comprises a water separating filter media.

44. The method of claim 41, comprising a vertical gap between a lower
portion of the first multi-layered filter media and a lower portion the
second multi-layered filter media, and allowing the coalesced water
droplets to exit the filter near the vertical gap.

45. (canceled)

46-59. (canceled)

Description:

PRIORITY

[0001]The present application is a Divisional of U.S. application Ser. No.
11/890816 filed Aug. 8, 2007, which is a Continuation of International
Application No. PCT/US2007/014397 the International Filing Date of which
is Jun. 20, 2007, which claims the benefit of priority of U.S.
Application No. 60/815118 filed Jun. 20, 2006 and U.S. Application No.
60/880145 filed Jan. 12, 2007. All of the aforementioned applications are
hereby incorporated by reference in their entirety.

TECHNICAL FIELD

[0002]The technical field related generally to fluid filters and to
methods and systems of removing unwanted particulates and/or water from
fluid with one or more filters

BACKGROUND

[0003]Fuel injection systems for internal combustion engines, such as high
pressure common rail fuel injection systems for diesel engines are
vulnerable to fuel contaminants, including particulates on the order of
4-6 microns and others such as larger and smaller particulates of various
phases and compositions which may be present in fuel. There is an unmet
need to reduce or eliminate these and other fuel contaminants.

SUMMARY

[0004]One embodiment is a filter element including an outer filter media
and an inner filter media. The outer filter media is operable to remove a
majority of the particulates present in a flow of fluid. The inner filter
element is operable to remove finer particulates from the flow of fluid
that pass through the outer filter media. In addition, the outer and
inner filter media comprises a multi-layered filter media. Other
embodiments include unique apparatus, devices, systems, and methods
relating to fuel filters and filtration. Further embodiments, forms,
objects, features, advantages, aspects, and benefits of the present
application shall become apparent from the detailed description and
figures included herewith.

BRIEF DESCRIPTION OF THE FIGURES

[0005]FIG. 1 is a side view of a vehicle including an internal combustion
engine system having a fueling system.

[0013]FIG. 9 is a cross-sectional view of another representative filter
cartridge.

[0014]FIG. 10 is a cross-sectional view of another representative filter
cartridge.

[0015]FIG. 11 is a cross-sectional view of a portion of the filter
cartridge depicted in FIG. 10.

DETAILED DESCRIPTION

[0016]For the purposes of promoting an understanding of the principles of
the invention, reference will now be made to the embodiment illustrated
in the drawings and specific language will be used to describe the same.
It will nevertheless be understood that no limitation of the scope of the
invention is thereby intended, such alterations and further modifications
in the illustrated device, and such further applications of the
principles of the invention as illustrated therein being contemplated as
would normally occur to one skilled in the art to which the invention
relates.

[0017]With reference to FIG. 1, there is illustrated an exemplary vehicle
100 including a passenger/operator cabin 102. As illustrated in FIG. 1,
vehicle 100 is a semi-tractor, but could alternatively be any of a
variety of other vehicles, such as a light, medium, or heavy duty truck,
bus, car, sport utility vehicle, motor coach, or farm or industrial
equipment, for example. In other embodiments, vehicle 100 could be a
marine or aircraft vehicle. Vehicle 102 includes a fuel tank 104 and
power/propulsion 106 that includes an engine 108. Additionally, system
106 includes a fueling system 110 coupled to a fuel tank 104 for
providing fuel to engine 108. A fluid conduit, pipe 112, or other flow
passage couples fuel tank 104 to fueling system 110. Engine 108 is
preferably a reciprocating piston type that is configured for compression
ignition and direct injection or port-injected diesel fueling. In other
embodiments engine 108 could be another type of engine, or power plant.

[0018]Referring to FIG. 2, fueling system 110 includes a first liquid
filtering subsystem 150, a fluid or fuel pump 152, and a second liquid
filtering subsystem 154. The first liquid filtering subsystem 150 is
positioned on the suction side of the fuel pump 152, and the second
liquid filtering subsystem 154 is positioned on the pressure side of the
fuel pump 152. Filtering subsystems 150, 154 provide clean, filtered fuel
that prevents pump wear, injector clogging, premature engine wear and can
boost fuel efficiency. The first liquid filtering subsystem 150 includes
a first set of filter assemblies 156 and the second liquid filtering
subsystem 154 includes a second set of filter assemblies 158. It should
be appreciated that system 110, and subsystems 150, 154 are exemplary,
and that a variety of other systems and subsystems are contemplated in
various embodiments. In some embodiments, only one filter subsystems 150,
154 having one filter in filter disclosed herein may be used.

[0019]The fuel tank 104 is in fluid communication with the first liquid
filtering subsystem 150. A check valve 160 is preferably positioned in
the fluid path between the fuel tank 104 and the filter assemblies 156.
Check valve 160 prevents fuel from flowing back into fuel tank 104 once
it leaves fuel tank 104 and enters the first liquid filtering subsystem
150. The first filtering subsystem 150 is positioned on the suction side
of the fuel pump 152. Filter assemblies 156 are capable of removing
contaminates from the fuel before they enter pump 152. The filter
assemblies 156 are connected in a parallel fluid flow path configuration.
Although illustrated in a parallel fluid flow path configuration, in
alternative arrangements, the filter assemblies 156 could be connected in
a series flow path configuration.

[0020]Fuel that is provided to engine 108 by fuel system 110 typically
includes some undesirable constituents or contaminants. Such constituents
typically include particulate matter, water, microorganisms and/or other
types of contaminates. To remove these constituents, liquid filter
assemblies 150, 154 are included in the fuel system 110. As set forth in
detail below, filter assemblies 156, 158 include a housing 200 defining
an interior space 202 for receipt of fuel and at least one filter element
250 (See FIG. 3) positioned within interior space 202 for filtering
constituents from the fuel. Filter elements 250 disclosed herein may be
used in various systems including, but not limited to, that disclosed in
U.S. Pat. No. 6,939,464, which is hereby incorporated by reference in its
entirety.

[0021]At least one filter assembly 156 may include a water-in-fuel ("WIF")
sensor 162. WIF sensor 162 is positioned in a lower portion of filter
assembly 156 and is used to detect water that is separated from fuel by
at least one filter assembly such as assembly 156. After a predetermined
amount of water is collected by filter assembly 156, WIF sensor 162
generates a signal that is sent to an engine control unit (not
illustrated). The engine control unit may then generate a signal, such as
lighting a warning lamp in the cab of vehicle 100, that indicates that
filter assembly 156 either needs to be changed, serviced, or drained. In
an alternative embodiment, filter assembly 156 automatically drains
collected water from filter assembly 156.

[0022]The first filtering subassembly 150 also includes an electric
priming and starting assist pump 164 in fluid communication with filter
assemblies 156. Priming and starting assist pump 164 is positioned
between the input to fuel pump 152 and the output of filter assemblies
156. Priming and starting assist pump 164 is used to help prime and start
engine 108 by supplying fuel during engine startup. A check valve 166 is
in fluid communication between the input to priming and starting assist
pump 164 and the output of priming and starting assist pump 164 as
illustrated. The check valve 166 prevents fuel from re-entering filter
assemblies 156 through the output of filter assemblies 156 when engine
108 is not running.

[0023]Fuel pump 152 is in fluid communication with a first and second
check valve 168, 170. First check valve 168 can be used to release fuel
back into the suction side of fuel pump 152 if the pressure rises above a
predetermined level. Second check valve 170 can be used to prevent fuel
from leaving or exiting the second filtering subsystem 154 if engine 108
is not running. Several different types of fuel pumps may be utilized in
different embodiments. A pressure sensor 171 is located downstream of the
output of fuel pump 152 before the input of the second filtering
subassembly 154. The pressure sensor 171 monitors the pressure of the
fuel as it exits fuel pump 152 and generates a signal indicative thereof
that is sent to the engine control unit.

[0024]The output of fuel pump 152, often referred to as the pressure side,
is in fluid communication with an input of the second filtering
subassembly 154. The second filtering subassembly 154 is preferably
designed to endure higher pressures than the first filtering subassembly
150. The first and second filtering subassembly 154 provides particulate
filtration and is capable of removing water from the fuel in some
embodiments. The second filtering subassembly 154 may include a frame
portion 172 that securely holds housings 200 of filter assemblies 158 to
vehicle 102. In one form, second filtering subassembly 154 may be placed
in an engine vibration isolation system 174 of the type disclosed in U.S.
Provisional Patent Application Ser. No. 60/744,895, filed Apr. 14, 2006,
entitled Vibration Isolated Fuel Filter Head, the disclosure of which is
hereby incorporated by reference in its entirety. As set forth therein,
the engine vibration isolation system 174 substantially reduces or
eliminates vibrations that may adversely affect operation of the second
filtering subassembly 154.

[0025]After exiting the second filtering subassembly 154, the fuel enters
a high pressure common rail system 176 which supplies fuel to engine 108.
A temperature sensor 178 is included in fluid communication with the
outlet of the second filtering subassembly 154. Temperature sensor 178 is
used to measure the temperature of the fuel before it enters the common
rail system 176. A check valve 180 is included in fluid communication
with the outlet of the second filtering subassembly 154. Check valve 180
is set to release fuel if the pressure in the fuel line rises above a
predetermined level. The fuel that is released by the check valve is
returned to fuel tank 104. Although the filters and filter elements
disclosed herein are described in connection with filtering fuel, it
should be appreciated that other types of fluid, such as lubricants for
example, could also be filtered by the filters and filter elements.

[0026]With reference to FIG. 3, there is illustrated a representative
replaceable filter element or cartridge 250 that is housed or positioned
within housing 200 of the first and/or second filtering subassembly 150,
154 set forth in FIG. 2. Filter element 250 includes a first or outer
filter media stage 252 and a second or inner filter media stage 254
radially spaced apart from outer filter media stage 252. Outer and inner
filter media stages 252, 254 extend vertically between an upper end plate
256 and a lower end plate 258. As illustrated, outer filter media stage
252 has a vertical length longer than that of inner filter media stage
254. In one form, outer filter media stage 252 and inner filter media
stage 254 comprise a multi-layer filter media. Using a multi-layer filter
media improves particle filtration efficiency.

[0027]According to a preferred embodiment, an upper portion 260 of outer
filter media stage 252 is fixedly secured to a lower surface 262 of upper
end cap 256 and a lower portion 264 of outer filter media stage 252 is
fixedly secured to a lower surface 266 of lower end cap 258. Likewise, an
upper portion 268 of inner filter media stage 254 is fixedly secured to a
second lower surface 270 of upper end cap 256 and a lower portion 272 of
inner filter media stage 254 is fixedly secured to a second lower surface
274 of lower end cap 258. The length or height of inner filter media
stage 254 is smaller than the length or height of outer filter media
stage 252.

[0028]Outer filter media stage 252, inner filter media stage 254, upper
end cap 256, and lower end cap 258 are generally cylindrical in shape,
but other shapes are envisioned. Outer and inner filter media stages 252,
254 may be fixed to the end caps 256, 258 in a variety of ways including,
but not limited to, embedding, potting with adhesive, or sonic, or
thermal welding. A centertube 276 may be coupled to an inside diameter
278 of inner filter media stage 254. Centertube 276 runs along the length
of inner filter media stage 254, but could be shorter than the length of
inner filter media stage 254. Centertube 276 includes a plurality of
apertures 279 that allow fluid to flow into an inner fluid chamber 281
defined by centertube 276. An inner surface area of outer filter media
stage 252 may also be aligned or connected with a second centertube 277
substantially designed the same as first centertube 276. In alternative
forms, centertube 276 may not be included.

[0029]Lower end cap 258 includes a lower base portion 280 and an upper
base portion 282. Lower portion 264 of outer filter media stage 252 is
secured to lower base portion 280 of lower end cap 258. A lower portion
272 of inner filter media stage 254 is secured to upper base portion 282
of lower end cap 258. Lower base portion 280 includes an outer flange 284
that protrudes upwardly from an outer edge 286 of lower end cap 258.
Upper base portion 282 of lower end cap 258 includes a second outer
flange 288 that also protrudes upwardly a short distance from an outer
edge 290 of upper base portion 282. Second outer flange 288 keeps inner
filter media stage 254 separated from outer filter media stage 252 such
that a gap 294 is formed between the two respective filter media stages
252, 254. Lower end cap 258 may be manufactured as one piece or two
pieces.

[0030]In one form, outer and inner filter media stages 252, 254 are formed
using a material that is selected to remove one or more undesirable
constituents or particulates by trapping or containing them relative to
filtered fuel downstream of such material. Further, outer and inner
filter media stages 252, 254 are preferentially formed from multiple
layers of particulate trapping material. As such, outer and inner filter
media stages 252, 254 comprise a multi-layered filter media. In another
form, inner and outer filter media stages 252, 254 comprise a melt blown
media, an air-laid media, a wet-laid media, a woven media, or a non-woven
media, a membrane media or a synthetic blend of one or more of the media
types.

[0031]Outer filter media stage 252 is a multi-layered filter media stage
that is operable to remove or capture unwanted contaminates or
particulates from a flow of fuel. Outer filter media stage 252 may be
larger or thicker than inner filter media stage 254 and is designed such
that, during operation, it is responsible for capturing a majority of the
unwanted particulates. In particular, in one form, outer filter media
stage 252 is designed to capture larger particulates contained in the
flow of fuel. Inner filter media stage 254 is also operable to remove or
capture unwanted contaminates or particulates from the flow of fuel. In
one form, inner filter media stage 254 contains multiple layers of
filtering media that are designed to remove smaller contaminates or
particulates that may not be captured or removed by outer filter media
stage 252. As such, in one form, outer filter media stage 252 removes a
majority of the contaminants by capturing the larger sized particles and
inner filter media stage 254 removes finer contaminates that may pass
through outer filter media stage 252.

[0032]In another form, outer filter media stage 252 comprises a coalescing
filter media operable to coalesce smaller water droplets into larger
water droplets. Outer filter media stage 252 is designed to withstand
high pressures and to merge water droplets contained in fluid passing
therethrough by using a coalescing medium as the filter media. The
coalescing filter media causes free water and emulsified water contained
in the fuel to form into larger droplets. Outer filter media stage 252
preferably utilizes the practice of liquid to liquid coalescence to merge
any water contained therein into larger water droplets. Fuel tends to
rise and water droplets fall, thereby providing clean fuel to engine 108.
The coalescing filter media may be based on cellulose, cellulose/glass
composite, meltblown media, airlaid media, wetlaid media, woven media,
non-woven media, membrane media or a synthetic blend of one or more of
the aforementioned media types. It should be appreciated that outer
filter media stage 252 and inner filter media stage 254 also filter
particulates from the flow of fuel.

[0033]Fuel introduced into filtering element 250 passes through an outer
surface 253 of outer filter media stage 252. As fuel travels through
outer filter media stage 252 water droplets are combined, preferably by
coalescing, to become larger water droplets. In addition, contaminates in
the fuel are also captured by outer filter media stage 252. As the fuel
and water droplets exit through an inner surface area 255 of outer filter
media stage 252, the water droplets separate from the fuel and flow
downwardly toward the bottom of filter element 250. Fuel or fluid
continues to flow to inner filter media stage 254 and the water settles
or flows downwardly to the bottom of gap 294.

[0034]In one form, the lower end plate 258 includes apertures or passages
that allow the water to flow out of filtering element 250. A gap 294
exists between outer filter media stage 252 and inner filter media stage
254 that assists in separation of water from the fuel by allowing
particles to further coalesce, for example due to inter-particle forces
and interactions, and other forces such as gravity and interaction with
other surfaces. In one form, the outer coalescing filter media 252
comprises a multi-layer filter media.

[0035]In another form, inner filter media stage 254 comprises a water
adsorbing, a water separating or a water coalescing media that removes,
adsorbs or separates any water droplets that may not flow to the lower
surface of gap 294 from the flow of fuel. In addition, inner filter media
stage 254 comprises a particulate filtering media capable of removing
particulates from the flow of fluid or fuel. As fluid passes through
inner filter media stage 254, the water absorbing media captures the
water droplets thereby removing them from the flow of fuel, for example
by wicking or by surface flow or by a combination or these and/or other
modes. In one form, the outer surface of filter media stage 254 may be
coated with or contain a water repellant or may be hydrophobic, which
further causes water to move through gap 294 toward the bottom of the
filtering element 250. As such, it should be appreciated that outer
filter media stage 252 can cause water droplets to be coalesced out of
the fuel stream.

[0036]The water droplets move toward a lower surface of filter element 250
and the fuel passes on through inner filter media stage 254. In another
form, the separator may have a hydrophobic outer surface of filter media
stage 254 with at least one downstream absorbing layer, such as a layer
of filter media containing a water absorbent polymer or like material. In
this form, water passing through the hydrophobic outer surface of filter
media stage 254 will be adsorbed by the water absorbing layer, causing it
to swell and increase the restriction across the filter. When the amount
of water and corresponding pressure drop becomes to high, flow to the
engine is restricted and the engine ceases to run, thus protecting the
engine from the detrimental effects of water. In another form, the in
filter media 254 comprises a multi-layer filter media that comprises
multiple layers of filtering media combined together to form water
separating media 254. In another form, the inner filter media 254
comprises a multi-layer filter media that comprises multiple layers of
filtering media combined together to form water separating media 254 to
capture water droplets that pass through the outer filter media stage 252
and gap 294 and coalesce them into larger drops that can be removed by
settling or downstream separator 254. In this case, the outer surface of
filter media stage 254 may be hydrophobic to further cause large water
droplets to move through gap 294 toward the bottom of the filtering
element 250 and be followed by subsequent hydrophobic or hydrophilic
layers to enhance coalescence.

[0037]In yet another representative form, inner filter media stage 254
comprises a coalescing filter media operable to coalesce water that may
pass through outer filter media stage 252 and gap 294. As such, in this
form, outer filter media stage 252 and inner filter media stage 254
comprise water coalescing stages or in other words, the filter element
250 includes dual coalescing stages. In other forms, outer filter media
stage 252 may include particulate removal filter media and inner filter
media stage 254 may include coalescing filter media. The coalesced water
will travel downwardly and the fluid or fuel will travel upwardly before
entering fluid chamber 281. As such, clean fluid or fuel free of water
will enter fluid chamber 281 to be used downstream. As with the previous
forms, both inner and outer filter media stages 252, 254 also capture
particulates in addition to coalescing water.

[0038]All of the embodiments disclosed herein may include filter media
stages that are operable to coalesce, adsorb water, separate water,
and/or capture particulate matter. In particular, outer and inner filter
media stages 252, 254, since they have multiple filter media layers, may
coalesce water, adsorb the coalesced water, separate water, and capture
particulates. Each layer of the filter media stages 252, 254 may be
designed to perform different functions.

[0039]Referring to FIGS. 3 and 4, a filter 300 is depicted which includes
filtering element 250. The filter 300 includes an outer shell or housing
302 that houses filtering element 250. An upper portion 304 of shell 302
includes an external seal 306, a nutplate 308, and an internal seal 310.
Seals 306, 310 and nutplate 308 have a generally cylindrical shape.
Internal seal 310 is fixedly secured to an upper surface 312 of upper end
plate 256. Internal seal 310 includes an L-shaped segment 314 that mates
with an L-shaped segment 316 of upper end plate 256.

[0040]Nutplate 308 includes an internal cylindrically threaded segment 318
that protrudes upwardly from a central axis of a base portion 320.
Threaded segment 318 includes an internally threaded portion 322. An
outer wing portion 324 of nutplate 308 extends upwardly and outwardly
from base portion 320 to an internal wall 326 of shell 302. Shell 302 may
comprise a permanent or disposable housing manufactured from various
compositions. A flange 328 protrudes upwardly from an end of wing portion
324. An upper portion 330 of shell 302 wraps around an upper portion of
flange 328 to secure shell 302 to flange 328 of wing portion 324.

[0041]External seal 306 is connected to an outer upper edge 332 of shell
302 and includes a downwardly extending segment 334 connected with an
inner edge 336 of nutplate 308. The external seal 306 seals filter 300 to
a respective externally threaded connector (not illustrated) in the fluid
path of fueling system 110. Inner seal 310 provides a fluid tight seal
between end cap 256 and nutplate 308.

[0042]Wing portion 324 includes a plurality of apertures 338 that run
circumferentially around the wing portion 324. During operation, fuel
enters the outer filtering media stage 252 through apertures 338. Fuel
then proceeds through the outer surface of outer filtering media stage
252. Fuel then exits outer filter media stage 252 and passes into gap 294
where the water droplets created by the coalescing media to move
downwardly while fuel moves upwardly. Fuel then enters inner filter media
stage 254 where any remaining water is preferably eliminated from the
flow of fuel.

[0043]Referring back to FIG. 3, upper end cap 256 of filter element 250
includes an upper surface 340 having an inside diameter 342 and an
outside diameter 344. An outer edge 346 of upper end cap 256 includes a
first flange 348 that protrudes downwardly a predetermined distance from
outer edge 346. The flange 348 secures a portion of an outer edge 350 of
the outer filter media stage 252 within first flange 348. An internal
segment 352 of upper end cap 256 extends downwardly from an inside edge
354 of upper end cap 256 to a base portion 356, preferably to form an
internal connection chamber 358.

[0044]The internal segment 352 also includes a downwardly extending
segment 359 that forms a flange that is secured to outer surface 296 of
inner filter media stage 254. A second flange 360 is located at an inner
edge 362 of base portion 356 and extends downwardly from inner edge 362.
Second flange 360 holds upper portion 268 of inner filter media stage 254
in place and is connected with an inside edge 364 of inner filter media
stage 254. Second flange 360 defines an aperture or opening that leads to
fluid chamber 281. Outer flange 348, downwardly extending 359 segment
353, and internal flange 360 form U-shaped cradles the same as or similar
to those illustrated in connection with lower end cap 258. The U-shaped
cradles are fixedly secured to respective ends of filter media 252, 254
as illustrated. Although U-shaped cradles are disclosed in the preferred
embodiment, the cradles may have other shapes in other embodiments.

[0045]Referring to FIGS. 5-8, in another form, upper end cap 256 includes
an outer flange 400 and an upper surface 426. Flange 400 is secured to
outside surface 401 of outer filter media stage 252. A base cap member
402 having a cylindrical outer wall 404 and a base 406 are connected to
an upper surface 408 of inner filter media stage 254. Base cap member 402
includes an inner flange 410, and a lower portion 412 of cylindrical
outer wall 404 defines an outer flange 414 that is secured to side 416 of
inner filter media stage 254. Inner flange 410 defines an opening 417 to
fluid chamber 281.

[0046]An upper cap member 418 having a downwardly extending flange 420, a
mid-section 422 and an upwardly extending flange 424 is connected to an
upper surface 426 of upper end cap 256. Downwardly extending flange 420
extends downwardly from an edge of mid-section 422 and is secured to the
inside surface of an upper portion of outer wall 404 of base cap member
402. Inner end cap member 418 may be connected to upper surface 426 and
outer wall 404 of base cap member 402 in a variety of ways including, but
not limited to, embedding, potting with adhesive, or sonic or thermal
welding. A cylindrical seal 428 is fixedly secured to a lower portion 430
of flange 420 that extends downwardly to base 406 of base cap member 402.

[0047]A nutplate 308 is connected with upper flange 424 of upper cap
member 418. A lower portion 434 of outer wing 324 and a lower portion 436
of base 320 are fixedly secured to upper cap member 418. Upwardly
extending flange 424 and base 320 may be connected with inner end cap
member 418 in a variety of ways including, but not limited to, embedding,
potting with adhesive, or thermal or sonic welding. An outer edge 438 of
outer wing 324 is connected with an inner surface 441 of shell 302. The
outer edge 438 positions end cap 256 such that a fluid path 440 is formed
between flange 400 and shell 302. As such, during operation, fuel enters
through apertures 338 of nutplate 308 and travels into a fluid chamber
442 where it is directed through fluid path 440 to outer filter media
stage 252.

[0048]Referring back to FIG. 4, a lower portion 380 of shell 302 includes
a spring 382 that is positioned within an interior space 384 of shell
302. The spring 382 is connected with an interior surface 386 of shell
302 and a lower surface 388 of lower base portion 390. The spring 382
applies upward force to lower surface 388 of lower base portion 390 to
force end plate 256 against upper cap member 418, upper cap member 418
against nutplate 308, and nutplate 308 against curved portion of shell
302. This further helps fixedly secure all of the respective components
or elements together.

[0049]Referring collectively to FIGS. 6 and 7, a portion of filtering
element 250 set forth in FIG. 5 is illustrated in further detail. Base
cap member 402 is connected with upper surface 408 of inner filtering
media stage 254. Base cap member 402 includes opposing flanges 410, 414
that extend downwardly from the outer and inner edge of base portion 406
of base cap member 402. Base cap member 402 also includes an upwardly
extending segment 404 that extends vertically upward from an outer edge
412 of base portion 406. Flange 414 secures the outer edge of inner
filtering media stage 254 to base cap member 402. Base portion 406, outer
flange 414, and inner flange 410 form a U-shaped cradle that secures base
cap member 402 to the upper portion of inner filtering media stage 254.

[0050]Upwardly extending segment 404 of base cap member 402 defines a
cylindrical upper chamber 443. Inner flange 410 of base cap member 402
defines a cylindrical lower opening 417. Base cap member 402 also
includes a plurality of oval shaped apertures 445 located near an upper
edge 447 of upwardly extending segment 404. As set forth below, potting
material or adhesive may be placed in and around apertures 445 to secure
base cap member 402 to the outer edge of outer filter media stage 252.

[0051]Referring to FIG. 8, a portion of filtering element 250 set forth in
FIGS. 6 and 7 is illustrated positioned within a portion of a filter 550.
As illustrated, an interior portion 552 of base cap member 402 has been
covered with a layer of potting material 554. Potting material 554
creates a fluid tight seal between base cap member 402 and upper cap
member 418 of filter 550. A second layer of potting material 556 may be
used to seal an inner junction 556 wherein the inner end plate member 418
connects with the lower surface of nutplate 324. A fluid supply tube 560
is illustrated positioned through opening 417 in base cap member 402 and
protruding down into fluid chamber 281.

[0052]Referring to FIG. 9, another embodiment of a filtering element 250
is illustrated. Filtering element 250 includes an inner filtering media
stage 600 and an outer filtering media stage 602 radially spaced
outwardly from inner filtering media stage 600. As previously set forth,
outer filter media stage 602 is formed from a material that is capable of
coalescing free water and emulsified water contained in a flow of fuel or
fluid. Inner filter media stage 600 is formed from a water separating
media that is capable of separating water from the flow of fuel so that
water does not flow downstream where it is utilized. In addition, outer
filter media stage 602 and inner filter media stage 600 are capable of
removing or capturing unwanted particulates from the flow of fuel or
fluid.

[0053]In other forms, inner filter media stage 600 is formed from a
material that is capable of coalescing free water and emulsified water
contained in a flow of fuel or fluid. As such, both outer filter media
stage 602 and inner filter media stage 600 may comprise coalescing filter
media. As such, in this form, filter element 250 has two filter stages
operable to coalesce water. In another representative form, outer filter
media stage 602 includes particulate filter media and inner filter media
stage 600 includes coalescing filter media. Inner filter media stage 600
and outer filter media stage 602 also capture unwanted particulates from
the flow of fluid or fuel.

[0054]Inner filter media stage 600 extends between a first lower end cap
604 and an upper end plate 606. First lower end cap 604 includes a pair
of opposing flanges 608 that extend upwardly from a base portion 610 of
first lower end cap 604. Flanges 608 and base portion 610 form a U-shaped
engagement member 612 that is secured to a lower portion 614 of inner
filter media stage 600. Inner filter media stage 600 may be secured in
U-shaped engagement member 612 and to a lower surface 616 of upper end
plate 606 by several attachment methods including, but not limited to,
embedding, potting with adhesive, and sonic or thermal welding. Although
U-shaped engagement members 612 are disclosed herein, it is envisioned
that engagement members 612 may have other shapes in other embodiments.

[0055]Outer filter media stage 602 extends between a second lower end cap
618 and upper end cap 606. Second lower end cap 618 includes a pair of
opposing flanges 620 that extend upwardly from a base portion 622 of
second lower end cap 618. Flanges 620 and base portion 622 form a
U-shaped engagement member 624 that is secured to a lower portion 626 of
outer filter media stage 602. Outer filter media stage 602 may be secured
in U-shaped engagement member 624 and to lower surface 616 of upper end
plate 606 by several attachment methods including, but not limited to,
embedding, potting with adhesive, and welding.

[0057]Although not illustrated, filtering element 250 can be positioned in
a shell 302 that includes a nutplate 324 similar to that disclosed in
previous embodiments. Lower end plate 606 includes a flange 628 that
extends upwardly from a base portion 630 of lower end plate 606. A
portion of an outer edge 632 of outer filter media stage 602 is connected
with flange 628 of lower end plate 606.

[0058]Referring to FIG. 10, a cross-sectional view of another
representative filter element 700 is illustrated. As in the previous
embodiments, filter element 700 includes an inner filter media stage 702
and an outer filter media stage 704. Outer filter media stage 704
coalesces water so that the water forms larger water droplets and inner
filter media stage 702 separates out any water that remains after leaving
outer filter media stage 704. As previously set forth, water droplets
that exit filter media stage 704 travel downwardly toward a lower surface
706 of filter element 700. Any water droplets that do not make it to
lower surface area 706 of filter element 700 enter inner filter media
stage 702 which removes them from the flow of fuel. In addition, inner
filter media stage 702 and outer filter media stage 704 remove unwanted
particulates from the flow of fluid.

[0059]Filter element 700 includes an upper end plate or cap 708 and a
lower end plate or cap 710. Upper end plate 708 comprises an upper cap
segment 712 and a lower cap segment 714. Upper cap segment 712 is
generally cylindrical in shape and includes a circular shaped male
connection member 716 that protrudes downwardly from a lower surface 718
of upper cap segment 712. Lower cap segment 714 is also generally
cylindrical in shape and has a smaller diameter than upper cap segment
712. Lower cap segment 714 includes a circular shaped female connection
member 720 that protrudes downwardly from a lower surface 722 of lower
cap segment 714. Male connection member 716 of upper cap segment 712 is
fixedly secured within female connection member 720 of lower cap segment
714.

[0061]Lower end plate 710 may comprise a unitary piece that includes a
first U-shaped cradle 728 and a second U-shaped cradle 730. First
U-shaped cradle 728 is used to secure a lower portion 732 of outer filter
media stage 704 to lower end plate 710. Second U-shaped cradle 728 is
used to secure a lower portion 734 of inner filter media stage 702 to
lower end plate 710. First U-shaped cradle 728 includes an outer flange
736 that protrudes upwardly from a base portion 738 of lower end plate
710. A second flange 740 protrudes upwardly from approximately the
mid-section of lower end plate 710. The first and second U-shaped cradles
728, 730 share second flange 740. Although U-shaped cradles are disclosed
herein, other shaped cradles are envisioned.

[0062]Third flange 742 protrudes upwardly from a second base portion 744
of second U-shaped cradle 730. Third flange 742 forms an opening 746 in
lower end plate 710 such that a fluid transfer tube 560 (for example as
shown in FIG. 8) may be inserted into an interior space 748 defined by
inner filter media stage 702. Seal 750 is fixedly secured to an outside
portion of third flange 742 and a lower portion 752 of second base
portion 744. Seal 750 provides a fluid tight seal between filter segment
700 and fluid transfer tube 560.

[0063]Referring to FIGS. 10 and 11, to assist in water separation in fluid
applications, inner filter media stage 702 has a first length ("L1") and
outer filter media stage 704 has a second length ("L2") which is longer
than first length L1. The difference between the first length L1 and the
second length L2 forms a vertical gap 754 between the bottom of inner
filter media stage 702 and the bottom of outer filter media stage 704. A
variety of different gap sizes are contemplated. A horizontal space or
gap 756 is provided between inner filter media stage 702 and outer filter
media stage 704. The second flange 740 of lower end plate 710 may include
a plurality of openings 758 that allow water to flow out of the bottom
surface of filtering element 700 through lower end plate 710.

[0064]While the invention has been illustrated and described in detail in
the drawings and foregoing description, the same is to be considered as
illustrative and not restrictive in character, it being understood that
only the preferred embodiments have been shown and described and that all
changes and modifications that come within the spirit of the inventions
are desired to be protected. It should be understood that while the use
of words such as preferable, preferably, preferred or more preferred
utilized in the description above indicate that the feature so described
may be more desirable, it nonetheless may not be necessary and
embodiments lacking the same may be contemplated as within the scope of
the invention, the scope being defined by the claims that follow. In
reading the claims, it is intended that when words such as "a," "an," "at
least one," or "at least one portion" are used there is no intention to
limit the claim to only one item unless specifically stated to the
contrary in the claim. When the language "at least a portion" and/or "a
portion" is used the item can include a portion and/or the entire item
unless specifically stated to the contrary.